Welds



May 16, 1967' J. B. JONES ETAL 3,319,934

WELDS Filed Oct. 26, 1964 7 Sheets5heet l E F. DE PRSSCO INVENTORS JAMES BYRON dONES CARMIN May 16, 1967 .1 B. JONES ETAL 3,319,934

WELDS Filed 00%.. 2a, 1964 7 Sheets-She'et 2 ZIO U g 9 g N o *I N j J T O 3; o

! INVENTORS JAMES BYRON JONES CARMINE F. DE FRISCO a w, BY

ATTORNEY y 1967 J. a. JONES ETAL 3,319,984

WELUS Filed on 26, 1964 '7 Sheets-Sheet 3 INVENTOKS JMWES BYRON JONES CARMENE F. DE FRISCO BTTQRNEY y 1967 .1. B. JONES ETAL 3,319,984

WELDS Filed Oct. 26, 1964 '7 Sheets-$heet 4 INVENTORS JAMES BYRON JONES GARMENE F. DE PRBSCO BY Wm gm ATTORNEY y 7 J. B. JONES ETAL 3,319,984

WELDS Filed Oct. 26, 1964 '7 Sheets-Sheet 5 I llllllbaq m.

INV EN TOR5 JAMES BYRON JONES ATTORNEY WELDS Filed Oct. 26, 1964 '7 Sheets-Sheet 6 4 I m, T 1 140 110 5 g, bio I l/34 IB2-W F M /E: %-Bo I28 1 I26 I38 j 136 INVENTORS' JAMES BYRON JONES GARMQNE F. DE $88560 BY AT TORNEY May 16, 1967 J. B. JONES ETAL 3,319,934

WELDS Filed Oct 26, 1964 7 Sheets-Sheet 7 IN VENTORS JAMES BYRON JONES BQARMINE F. DE FRISCO g m I ,"k-

ATTORNEY United States Patent Ofifice 3,319,984 ?atented May 16, 1967 3,319,984 WELDS James Byron Jones. West Chester, and Carmine F. De

Prisco, Glen Mills, Pa., assignors to Sohobond Corporation, West Chester, Pa., a corporation of Pennsylvania Filed Oct. 26, 1964, Ser. No. 406,521 9 Claims. (Cl. 287-18936) This is a continuation-in-part of application Serial No. 739,555 filed on June 3, 1958, now Patent No. 3,184,841, and entitled, Method and Apparatus Employing Vibratory Energy for Bonding Metals and Metal Weldments Formed Thereby.

This invention is directed to method and apparatus employing vibratory energy for bonding metals together and to metal weldments formed thereby, and more particularly to method and apparatus employing torsional vibratory energy.

Vibratory welding processes and apparatus have been described in Patents 2,946,119 and 2,985,954. The disclosures of each of the above-identified patents and the above-identified patent application are incorporated into the subject patent application and made a part hereof.

Where it is desired to encapsulate various types of devices such as transistors, medicaments, surgical items (such as needles and sutures), etc., it often requires eX- pensive and complex fiXturin to accomplish ring-type welds by means of seam-welding equipment.

Moreover, for structural purposes, any spot-type weld requires that the load associated with one portion of the weldment be carried into the other portion of the weldment through the spot-type junction which may offer a lesser cross-section than is desirable. Thus, when forces are carried from one metal member to another metal memher through a spot-type junction, whether it be a spottype weld or a bolt, rivet, staple, or other mechanical fastener, there is a reduced capacity for transferring the load which, in engineering terms, is described as joint efliciency, to compare the strength of the joined assembly with the theoretical strength of the same geometry having no joint. When such structural elements are required to transmit vibration loads or variable loads, as is commonly found in aircraft, failure can be expected adjacent to the reduced area junction, whether it be a bolt, rivet, or a spot-type weld. It is therefore desirable for structural purposes that the largest possible area of the members of the junction be connected. Thus, in the case of weldments, instead of using a spot-type Weld, a ring-type weld is one means for efiecting greater joint efiiciencies. When the junction is a solid-state metallurgical junction instead of a metallurgical junction involving a cast-type structure, as for example is the case with resistance spot welding, the advantages are still further enhanced.

We have found that, using novel ultrasonic techniques and equipment, ring-type junctions can be accomplished with a single weld pulse instead of a series of pulses as is required for making overlapping spots or continuous-seam welds.

We have found in particular that such junctions are useful in connection with the encapsulation of transistors, medical and surgical items, and in the fabrication of structural components, etc.

In the hermetic encapsulation of highly delicate items or elements of extreme purity, such as semiconductors, etc., it is essential that the purity of the atmosphere in the capsuie be maintained. With ordinary resistance welding there is usually a small amount of arcing, sputtering, or spattering associated with the accomplishment of such weld. Some of the expulsion therefrom goes into the capsule and some goes outside of the capsule. That going into the capsule constitutes a contaminant in the form of gas, metallic ions, etc., which is highly undesirable, particularly in the case of encapsulated semiconductors.

Vibratory welding is accomplished by the use of torsional vibration rather than by the means set forth in the aforesaid patent applications. The torsional vibration of bars is discussed from a theoretical point of view at pages 64 and 65 of Harry F. Olsons book, Acoustical Engineering, second edition, published in 1947 by D. Van Nostrand Company.

Welding in accordance with the present invention employing torsional vibration may be effected under the conditions heretofore generally developed and set forth in the above'identified patents and patent application for vibratory welding.

Welding is effected under a clamping force sufiicient to hold the metals being welded in firm contact at the intended weld interface.

The clamping force may thus be varied over a wide range. Thus, in a preferred embodiment, the maximum clamping forces need not produce an external deforma tion 1 of more than about ten percent in weldments eftested at room or ambient temperatures. In many cases the extent of deformation is appreciably below 10% and in some instances may be virtually absent altogether. The minimal clamping force to be used in the process of this invention constitutes a force sufiicient to maintain the metals being welded in regulated alignment and firm contact, e.g. contacting each other so that the weld may be effected by the application of vibratory energy.

The range of operative clamping pressures which may be employed may be readily ascertained by the user of the process. In all cases the clamping force must be sufiicient to elfect coupling between the metals being Welded and the source of vibratory energy, so that such vibratory energy may be transmitted to the metals.

The operative range of vibratory welding frequencies which may be used includes frequencies within the range 59 to 300,000 cycles per second, with the preferred range constituting 400 to 90,000 cycles per second, and the optimum operating frequency range lying between about 5,000 to 75,000 cycles per second. This optimum range of operating frequencies may be readily achieved by transducer elements of known design, which are capable of generating elastic vibratory energy of high intensity.

Welding may be and in many instances is initiated at room temperatures or ambient temperatures without the application of heat. if desired, welding may also be initiated at elevated temperatures below the fusion temperature (melting point or solidus temperature of any of the pieces being bonded). Thus, heating the metals to be welded prior to, and/or during welding to a temperature below their fusion temperature may, in some cases, facilitate the ease of welding and lower the power requirements and/or time requisite to achieve Welding. The welding process is used to form ring-type or unweldedcenter-type spot welds and is also applicable to forming seam welds which are accomplished by overlapping said ring-type or unwelded-center-type welds.

By deformation is meant the change in dimensions of the Weldment adjacent the weld zone divided by the aggregate thickness of the weldmen-t members prior to welding; result multiplied by to obtain percentage.

-The weldment may be warm to the touch after the weld due to the application of the elastic vibratory energy.

3 The temperatures to which the foregoingstatements refer are those which can be measured by burying diminutive thermocouples in the weld zone prior to welding, as well as the temperatures which can be estimated 01' approximated from a metallographic examination of a cross-section of a vibratory weld in the ordinary magnification range up to about 500 diameters,

The welding process may be applied to a variety of metals and alloys, examples of which include: aluminum to aluminum; aluminum alloy to aluminum alloy; nickelplated low-carbon steel to gold-plated iron-nickel'cobalt alloy; copper to copper; aluminum alloy to iron-cobaltvanadium alloy; etc.

The ring-type or unwelded-center-type welding process embodiment may be accomplished within a wide time range, such as a time range of between about 0.0001 second to about 6.0 seconds, with welding under most normal conditions being effected during a time interval of from several hundredths of a second to several seconds.

The welding of most metals can be effected in the ambient atmosphere. However, the process comprehends welding under vacuum conditions or in selected conditions such as atmosphere comprising an inert gas. Furthermore, while the welding process may be effected with metals, such as aluminum, without the extensive precleaning required to effect satisfactory welding by other methods, a degree of precleauing and surface treatment may prove advantageous in the welding of many metals. It is desirable prior to effecting welding in accordance with the present invention to remove surface contaminants, such as hydrocarbon and other lubricants and the like.

By virtue of the vibratory welding invention utilizing torsional vibration it is possible to effect peripheral or circumference-type welding without resort to continuousseam welding techniques.

The weldments of the present invention produced by the method and apparatus of the present invention include ring-type or annular welds, that is a weld between two metallic objects wherein the weld zone comprises a substantially circular ring, and also discontinuous circular welds, that is a ring-type weld in which the weld is broken in one or more places.

This invention has an weld.

This invention has as another object the provision of an annular weld having a non-welded center portion.

This invention has as yet another object the provision of a novel spot weld which may be arcuate, round, elliptical, square, etc., but lacking a welded central portion.

This invention has as still another object the provision of novel weldments.

Other objects will appear hereinafter.

For the purpose of illustrating the invention there are shown, in the drawings, forms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.

Referring to the drawings wherein like reference characters refer to like parts:

FIGURE 1 is a sectional view of one embodiment of a vibratory welding transducer-coupling system of the present invention.

FIGURE 2 is a view taken on line 22 of FIGURE 1.

FIGURE 3 is a sectional view of another embodiment of the vibratory welding transducer-coupling system of the present invention.

FIGURE 4 is a sectional view of another embodiment of the vibratory welding transducer-coupling system of the present invention.

FIGURE 5 is a section taken on line 55 of FIG- URE 4.

FIGURE 6 is a sectional view of another embodiment of the vibratory welding transducer-coupling system of the present invention.

FIGURE 7 is a plan view looking upward taken on line 77 of FIGURE 6.

FIGURE 8 is a perspective view of a tip used for making a discontinuous ring-type weldment.

FIGURE 9 is a plan sectional view through a weldment elfected with the tip of FIGURE 8.

FIGURE 10 is a sectional view revealing diagrammatically the method and apparatus for forming a particular weldment in accordance with the present invention.

object the provision of a novel FIGURE 11 is a sectional view revealing diagrammatically another form of apparatus for forming a particular weldment in accordance with the present invention.

FIGURE 12 is an elevational view, partly in section, of a transistor whose cap and base have been welded together in accordance with the present invention.

IGURE 13 is an elevational view revealing the apparatus for effecting the welding of the cap and body of the transistor of FIGURE 12.

FIGURE 14 is an enlarged sectional view of the portion of FIGURE 13 shown in the region intermediate the arrowheads designated as 14 in FIGURE 13.

FIGURE 15 is a section taken on line 1515 of FIG- URE 13.

FIGURE 16 is an elevational view of another embodiment ofthe vibratory welding transducer-coupling system of the present invention.

FIGURE 17 is a photomicrograph through a weldment of the present invention enlarged one hundred and fifty times.

FIGURE 18 is a photomicrograph of the weldment shown in FIGURE 17 enlarged five hundred times.

FIGURE 19 is a partial plan View of a weldment between two metal members in accordance with another embodiment.

FIGURE 20 is a partial plan view of a weldment between two metal members in accordance with another embodiment.

Referring to the drawings and initially to FIGURES 1 and 2 there is shown therein the vibratory welding transducer-coupling system disignated generally as 10.

The metal workpieces 12 and 14 are welded together in accordance with the process of the present invention intermediate the sonotrode 16 and the torsionally rigid anvil 18. By torsionally rigid is meant a body that will not readily respond to torsional excitation.

The sonotrode 16 in the illustrated embodiment shown in FIGURE 1 comprises a cylindrical tube or rod which is supported by the mass 20. The engagement between the mass 20 and the sonotrode 16 occurs at a true node on the sonotrode 16, as at one-quarter wavelenght in torsion or odd unit multiples of one-quarter wavelength in torsion from the free end 22 of sonotrode l, it being known that attachment of supporting means for vibratory systems at true nodes on said systems is desirable and it having been discovered that true nodes are available at the positions indicated since the free end 22 of sonotrode 16 delivers little or no power to air. The portion of sonotrode 16 intermediate the region of engagement with the mass 29 and the free end 22 is received Within an opening 26 within the mass 20.

The internal diameter of the opening 26 of the mass 29 is substantially larger than the outside diameter of the sonotrode 16, except for a small annular constriction 26a which permits the countcrbore to receive the flange 24 of the sonotrode 16. The flange 24 of the sonotrode 16 must be rigidly, preferably metallurgically as by brazing or welding, attached to the mass 20 in the counterbore of the constriction 26a.

The force necessary to maintain the metal workpieces 12 and 14 being welded in regulated alignment and firm contact is designated diagrammatically as F and may be supplied in practice by suitable mechanical means which may consist of spring means, compressed air cyliuder means, hydraulic cylinder means, and the like.

The lowermost end of sonotrode 16 may be provided with an annular tip 23 which is secured to the sonotrode 16, preferably metallurgically, as by brazing or the like. The lowermost face of annular tip 28 engages the metal workpieces 12 and 14 undergoing welding.

The sonotrode 16 is provided with an integral radially outwardly projecting flange 3%) at the driving point which is at a position corresponding approximately to a loop on said sonotrode 16. Thus, in the illustrated embodiment the sonotrode 16 has an over-all length of one wave-- length in torsion at the first overtone or second harmonic or its frequency of ope-ration. The free end 22 of sonotrode 16 and the annular tip 28 are both approximately at loops on said sonotrode 16. The flange 30 is onehalf Wavelength from free end 22 (or one-half wavelength from annular tip 28) and hence is also positioned at a loop, the first overtone or second harmonic having been chosen for convenience in connection with the positioning of the various elements of the system. However, the sonotrode 16 may be constructed to operate at other modes of torsional vibration and the various elements of the system positioned accordingly, as will be explained below. For a given frequency of torsional vibration (h) the equation for the sonotrode 16 is:

where l is the length of the sonotrode 16 in centimeters, p is its density in grams per cubic centimeter, Q is Youngs modulus in dynes per square centimeter, and D is Poissons ratio. The overtones are harmonics of the fundamental, and f2= fn f3= fn f4= fn Tne sonotrode 16 is torsionally vibrated by means of the spaced transducers 32 and 34 and their respective couplers 36 and 38, said couplers 36 and 38 being designed to vibrate longitudinally at the same frequency as the sonotrode 16 and being dimensioned, therefore, according to equations already known to the art, as explained in the above-cited patent applications.

The coupler 36 is a tapered metallic element, brazed or otherwise metallurgically secured in end-to-end engagement with transducer 32, and slotted at its small end, at which end it is metallurgically joined, as by brazing, to flange 30 of sonotrode 16 (see in particular FIGURE 2 wherein it will be seen that the coupled member 36 engages about one-fourth of the periphery of flange 36). The coupler member 38 is similarly metallurgically secured in end-to-end engagement to transducer 34, and similarly partially encircles and is metallurgically secured to flange 30 of sonotrode 16, the points of engagement of the coupled members 36 and 38 to the flange 39 being opposed in respect to each other. These tapered coupler members 36 and 38, the cross-section of which may vary, and which may be round, square, or rectangular, may be one-half wavelength long longitudinally or may have a length equal to unit multiples of one-half wavelength longitudinally.

The transducers 32 and 34 each comprise a laminated core of nickel or other magnetostrictive metallic material. Each of the transducers 32 and 34 has a rectangularly shaped opening in its center portion, namely rectangularly shaped opening 49 in transducer 32 and rectangularly shaped opening 42 in transducer 34. A polarizing coil and an excitation coil may be wound through the rectangularly shaped opening in each of the transducers 32 and 34; thus, the polarizing coil 44 and the excitation coil 46 are wound through the rectaugularly shaped opening in transducer 32 and the polar zing coil 48 and the excitation coil 50 are wound through the rectangular opening 42 in the transducer 34. Upon variations of the magnetic field strength of the excitation coils there will he produced concomitant variations in the dimensions of the transducers, provided their polarizing coils are charged at a suitable level with DC. current, and it will be appreciated by those skilled in the art that the frequency of the aforesaid variations, namely the expansion and/or contraction of the magnetostrictive transducers will be equal to the frequency of the alternating electric current flowing in their excitation coils.

The transducers 32 and 34 are each dimensioned to precisely identical dimensions as are the coupler members 36 and 38 so that the vibratory energy delivered to the sonotrode 16 from transducer 32 and coupler member 36 and from transducer 34 and coupler member 38 is identical, for reasons of symmetry. The transducers 32 6 and 34 are driven in phase with each other, namely both transducers 32 and 34 are either simultaneously expanding or simultaneously contracting.

It is to be understood that the transducers 32 and 34 should be properly dimensioned to insure axial resonance with the frequency of the alternating current applied thereto, so as to cause them to decrease or increase in length according to their coeificients of magnetostriction. The coupler members 36 and 38 should resonate in length at the operating frequency of the transducers, so that the vibratory Welding transducer-coupling system 10 may operate efiiciently under the welding process conditions. Moreover, the sonotrode 16 should resonate in torsion at the frequency of the transducers 32 and 34 and couplers 36 and 38 to minimize energy losses.

In place of the transducers 32 and 34 shown in the drawings, other magnetostrictive materials may be used such as the alloy 2-V Permendur (an iron-cobalt alloy), a nickel-iron alloy, or Alfenol (an aluminum-iron alloy), each of which should be properly dimensioned to insure axial resonance with the frequency of the alternating current applied thereto, so as to cause it to decrease or increase in length according to its coefiicient of magnetostriction. Transducers of the aforesaid type presently constitute a preferred embodiment for operation at frequencies of up to about 75,000 cycles per second, although they may be used at higher frequencies. In place of the aforesaid metallic magnetostrictive materials, the transducer may comprise almost any material which has good physical properties and Which changes its physical dimensions under the influence of electric potential or electric current. Thus, it may comprise a piezoelectric material, such as quartz crystals, or an electrostrictive material such as barium titanate, lead zirconate, etc. Such materials presently are preferably used at high frequency operations, as at frequencies above about 75,000 cycles per second, although they can be used at lower frequencies. The transducer may also consist of ferro-electric materials or an electromagnetic device, such as that which actuates a radio loudspeaker.

In operation the transducer 32 and coupler 36 and the transducer 34 and the coupler 38 vibrate sonotrode 16 torsionally. Thus, there is oscillating peripheral or circumferential motion of the sonotrode 16. The oscillating peripheral or circumferential motion of the tip portion 28 during the torsional vibration of the sonotrode 16 is in phase with the oscillating peripheral or circumferential motion of the free end portion 22 of the sonotrode 16, but is degrees out of phase with the motion of the driven flange 30 which is metallurgically joined to the couplers 36 and 38 when the first overtone or second harmonic of torsional vibration construction is used.

Construction and operation of the sonotrode 16 to conform to the fundamental or first harmonic of torsional bar vibration has the disadvantage of offering but a single node and no loops intermediate the ends of the sonotrode 16. Operations may be effected at other overtones where a larger number of loops intermediate the ends of the sono trode is desired, for clearance purposes or for embodiments in which coupling to a large number of spaced couplers-transducers is effected to increase the power of the vibratory welding equipment. For example, three nodes and four loops are provided from one end of sonotrode 16 to the other when operation is effected at the second overtone or third harmonic.

As the fact of annular tip 28 which is juxtaposed to the uppermost surface of metal workpiece 12 vibrates, it delivers energy to the plane of the contacted area of the metal workpiece 12. This effects vibratory welding between the metal workpieces 12 and 14 in the region in which the same are engaged with the annular tip 28, producing a ring-shaped weld.

For example, under an applied clamping force of three hundred pounds it is possible to effect a ring-shaped weld nineteen thirty-seconds of an inch in outside diameter with the welded band being five sixty-fourths of an inch wide in two sheets of 0.012-inch 1100I-I14 aluminum alloy using a welding tip of the aforesaid configuration and commencing the weiding at room temperature with the welding time extending for a second and one-half at a power level of 500 watts at a frequency of 20,000 cycles per second.

Photomicrographs enlarged 150 and 500 times respectively through such weldment are shown in FIGURES 17 and 18.

As seen in FIGURE 18 the weldment lacks a fusion cast structure when magnified 500 times and presents an interfacial region that is highly disturbed.

In the embodiment shown in FIGURE 3, the vibratory welding transducer-coupler system a generally resembles the vibratory welding transducer-coupler system 10 of FIGURES 1 and 2 except that the coupler members 360 and 38a, which otherwise resemble the coupler members 36 and 38, are secured to the sonotrode 16 at the loop on said sonotrode 16a located at its lowermost end, e.g., adjacent to the weldment. Thus, the flange 30a instead of being positioned one-half wavelength in torsion from the free end 22a of sonotrode 16a as is flange 30 in vibratory welding transducer-coupler system 10 is positioned closely adjacent the tip 28a, this construction again being applicable to the case of operation of the sonotrode 16 at the first overtone or second harmonic of torsional bar vibration. A similar construction could be achieved at the fundamental or at the second overtone, if clearance at the work area is not a problem.

The only other difference between the vibratory welding transducer-coupler system 10a of FIGURE 3 and the vibratory welding transducer-coupler system 10 of FIG- URES 1 and 2 is that the sonotrode lea comprises a solid rod instead of a tube like the sonotrode 16; and the tip 28a presents a full face to the workpieces 12a and 14a undergoing welding, rather than an annular face as is presented by the tip 28 of vibratory welding transducer-coupler system 10. However, even with a full-faced tip, a ringshaped weld is produced because of the nature of torsional vibration of the sonotrode 16a In the embodiment shown in FIGURES 4 and 5, the vibratory welding transducercoupler system 10b generally resembles the vibratory welding transducer-coupler system 10 of FIGURES 1 and 2, except that in place of a pair of opposed coupler members 36 and 38 and their respective magnetostrictive transducers 32 and 34, there is subsittuted a single coupler member 38b and a single magnetostrictive transducer 34b. The magnetostrictive transducer 34b of vibratory welding transducer-coupler system 10b generally resembles the magnetostrictive transdueer 34 of the vibratory welding transducer-coupler system 10 of the embodiment shown in FIGURES 1 and 2. However, the coupler member 3817 instead of being provided with a slotted end which receives a mating flange carried by the sonotrode, as in vibratory welding transducer-coupler system 10, is provided with a tongue 52 of reduced dimensions which is received within a slot 54 cut into the sonotrode 16b. The tongue 52 is metallurgically joined, as by brazing, to the slot 54. The slot 54 replaces the flange 30 used in vibratory welding transducer-coupler system 10. Thus, the slot 54 is located at a loop on sonotrode 16b. The slot 54 in the illustrated embodiment is located one-half wavelength from the annular tip 2812 at the lowermost end of the sonotrode 16b, if the sonotrode 16b is constructed to operate at the first overtone or second harmonic of torsional bar vibration.

Expansion and contraction of the magnetostrictive transducer 34b will be transmitted through the coupler member 38b to the sonotrode 16b resulting in torsional vibration of such sonotrode 16b so as to result in welding together of the metal workpieces as heretofore described, under the outlined auxiliary conditions of force, time, etc. The vibratory welding transducer-coupler system 10b is of more economical construction than the vibratory welding transducer-coupler system 10, and may be used satisfactorily where the power requirements to effect vibratory welding are low. Where vibratory welding at higher power levels is desired, vibratory welding transducercoupler system 10 or other higher power systems to be described hereinafter should be utilized.

In FIGURES 6 and 7 there is shown another embodiment 10c of the vibratory welding transducer-coupler system of the present invention. The vibratory welding transducer-coupler system resembles the vibratory welding transducer-coupler system 10 of FIGURES 1 and 2 except that four couplers instead of two are attached to the sonotrode. The sonotrode 16c includes at a loop area a flange, namely the flange 56. The coupler members 36c and 380 are metallurgically joined to flange 56 of sonotrode 16c in the identical fashion in which the couplers 36 and 38 were joined to the flange 30 of sonotrode 16 of vibratory welding transducer-coupling system 10 of the embodiment shown in FIGURES l and 2. Each of the couplers 36c and 380 is provided with a magnetostrictive transducer, namely the respective magnetostrictive transducers 32c and 340 which are secured in end-to-end engagement with such couplers in the same manner as the magnetostrictive transducers 32 and 34 are secured to the couplers 36 and 38 of the vibratory welding transducer-coupler system 10 shown in FIG- URES l and 2. Also attached to flange 56 are couplers 36cc and 38cc which, as seen from FIGURE 7, are preferably disposed in ninety-degree space relationship to the couplers 36c and 38c. The couplers 36cc and 3800 carry the magnetostrictive transducers 32cc and 34cc at their respective ends. The metallurgical joinder of the magnetostrictive transducers to the couplers and of the couplers to the sonotrode is identical to that by which the couplers 36 and 33 are joined to flange 30 of sonotrode 16 and the magnetostrictive transducers 32 and 34 are joined to the couplers 36 and 38 in the vibratory welding transducer-coupler system 10 of FIGURES l and 2, except that space has been provided for the additional two couplers by moderately shortening the contact are between flange 56 and the grooved portions of the coupler tips. In a similar manner, a greater number of couplers may be attached to sonotrode 160, as a total of five or six or seven couplers or even as many as eleven or twelve. Likewise, a second flange may be provided at another loop area on the sonotrode 16c, and one or more couplers may be attached at one flange with one or more other couplers attached at another flange, bearing in mind the physical limitations of the system according to the materials used and so as to provide torsional vibration of the sonotrode 160. The vibratory welding transducercoupling system 100 permits welding operations in accordance with the method of the present invention .to be effected at high power levels, since a multiple number of magnetostrictive transducers and their associated couplers may be utilized.

As heretofore noted, the vibratory welding transducercoupling systems of the present invention may be used to produce discontinuous ring-type weldments as well as continuous ring-type weldments. In order to produce a discontinuous ring-type weldment, an annular tip may be used having shallow notches disposed in such tip. FIG- URE 8 reveals a notched tip 66 which may be carried on any of the vibratory welding transducer-coupling system embodiments herein described. In the particular embodiment shown in FIGURE 8, the tip 66 comprises an annulus which is shallowly notched in three places at 68, 7 0 and 72.

This tip 66 produces a weldment of the type shown in FIGURE 9, which is a plan view through a weldment 73 in which there is no metallurgical joinder in the portion of the weldment 73 which is juxtaposed to the notched-out parts of the tip. While the non-welded portions of the weldment 73 may not precisely conform with the notchedout portions of the tip, the degree of conformity is substantially close enough so that for most practical purposes the tip may be notched to the degree to which the discontinuities in the ring-type weldment 73 are desired. Thus, in the illustrated embodiment, the notches 68, 70 and 72 in the tip 66 are reflected in the discontinuities 68a, 70a, and 72a in the broken ring-type weld 73 produced by the use of such tip 66.

In FIGURE there is shown diagrammatically the vibratory welding of a flared tube 74 to a bored plate 76. The vibratory welding transducer-coupling system used to effect such welding may be vibratory welding transducer-coupling system 14) having the annular tip 28. However, in place of anvil 18, an anvil 78 is utilized, which anvil includes a guide passageway 89 through which the flared tube 74 extends. The anvil 78 may be in several pieces, e.g., split like a collet, for effecting facile insertion of the tube and removal of the weldment. Alternatively, if the bored plate 76 is sufficiently heavy, it can be supported in any convenient manner without resorting to a specific anvil configuration.

To effect the weldment shown in FIGURE 10 in sawtooth line, the plate 76 is positioned on support 78 with the flared end 82 of the tube 74 juxtaposed to the uppermost surface of plate 76. Upon torsional vibration of sonotrode 16 wit-h its tip 28 under the welding conditions heretofore set forth, the flared end 82 is vibratorily welded to the juxtaposed portion of plate 76 throughout its entire periphery.

In FIGURE 11 there is shown the welding of a flared tube 84 to a bored and countersunk metal plate 86. The fiared end 88 of tube 84 is welded to the juxtaposed surface of the countersink in metal plate 86 by means of the action of annular tip 282. The annular tip 28e may be carried in a vibratory welding transducer-coupling system which is otherwise identical to vibratory welding transducer-coupling system 10. The only difference between annular tip 28e and the annular tip 28 of vibratory welding transducer-coupling system 10 is that the end face 90 of annular tip 28e is contoured to mate with the juxtaposed face of flared end 88. The tube 84 extends through a passageway 92 in anvil 94. The metal-plate 86 is supported on the flat uppermost surface of anvil 94. As in FIGURE 10, the anvil may be in several pieces or may be dispensed with in favor of other convenient support means. Upon torsional vibration of the sonotrode with its tip 28e, vibratory welding is effected between the juxtaposed surface of the countersink and the outside surface of flared end 88 of tube 84, such weld being diagrammatically indicated by a sawtooth line.

As will be seen from FIGURES 10 and 11, it is possible by using the vibratory welding processes and apparatus of the present invention to readily effect weldments which cannot be readily made by other processes and apparatus.

In FIGURE 12 there is shown the transistor 90' comprising the envelope or case 92 formed from the cap 94 and the base 96. A plurality of leads 98, 1130, and 102 extend through the base 96 to the semiconductor element 104. Three leads 98, 100, and 102 are shown in FIGURE 12, but it is to be understood that a different number of such leads may be present depending upon the particular component to be welded. Base 96 has within it a fired ceramic insulation. It is essential for the satisfactory operation of semiconductor devices that chemical purity be maintained within the envelope 92. Prior used fusion welding and soldering techniques for joining the cap 94 to the base 96 produce gaseous or ionic contamination within the envelope 92 of the transistor 96. However, We have found that by torsionally welding the cap 94 to the base 96 at the annular flange 98 of the cap 94 in accordance with our invention contamination by the welding operation can be avoided.

As shown in FIGURES 13, 14 and 15, the vibratory welding transducer-coupling system 196 of the present invention used to effect the aforesaid weldment comprises the sonotrode 188 which comprises a cylindrical tube or rod which is supported by the mass 110. The engagement between the mass and the sonotrode 108 occurs at flange 111 positioned on a true node on the sonotrode 108, as at one-quarter wavelength in torsion or odd unit multiples of one-quarter wavelength in torsion from the free end 112 of sonotrode 188, it being known that attachment of supporting means for vibratory systems at true nodes on said systems is desirable and it having been discovered that true nodes are available at the positions indicated since the free end 112 of sonotrode 103 delivers little or no powewr to air. The portion of sonotrode 188 intermediate the region of engagement with the mass 110' and the free end 112 is received within an opening 114 within the mass 110.

The internal diameter of opening 114 of the mass 110 is substantially larger than the outside diameter of the sonotrode 188, except for a small annular constriction 114a which permits the counterbore to receive the flange 111 of the sonotrode 1%. The flange 111 of the sonotrode 1438 must be rigidly, preferably metallurgically as by brazing or welding, attached to the mass 110 in the counterbore of the constriction 114a.

The force necessary to maintain the cap 94 and base 96 of the metal envelope 92 of the transistor 98 which are being welded together in regulated alignment and firm contact is designated diagrammatically as F and may be applied in practice by suitable mechanical means which may consist of spring means, compressed air cylinder means, hydraulic cylinder means, and the like.

The lowermost end of the sonotrode 1% may be provided with an annular tip 118 which is secured to the sonotrode 188, preferably metallurgically, as by brazing or the like. The lowermost face of annular tip 118 engages the flange 98 of the cap 94. The raised portion of the cap 94 projects into the opening formed in the sonotrode 108. The sonotrode 188 is provided with an integral radially outwardly projecting flange 126 at the driving point which is at a position corresponding approximately to a loop on said sonotrode 188. Thus, in the illustrated embodiment the sonotrode 188 has an over-all length of one wavelength in torsion at the first overtone or second harmonic of its frequency of operation. The free end 112 of sonotrode 188 and the annular tip 113 are both approximately at loops on said sonotrode 188. The flange 120 is one-half wavelength from free end 112 (or one-half wavelength from annular tip 118) and hence is also positioned at a loop, the first overtone or second harmonic having been chosen for convenience in connection with the positioning of the various elements of the system. However, the sonotrode 198 may be constructed to operate at other modes of torsional vibration and the various elements of the system positioned accordingly, as explained heretofore. For a given frequency of torsional vibration (h) the equation for the sonotrode 108 is:

f1 21 p 1+1 where l is the length of the sonotrode 168 in centimeters, p is its density in grams per cubic centimeter, Q is Youngs modulus in dynes per square centimeter, and 0' is Poissons ratio. The overtones are harmonics of the fundamental, and f2= fn fa= fn f4= fn The sonotrode 188 is torsionally vibrated by means of the spaced transducers 126 and 128 and their respective couplers 122 and 124-, said couplers 122 and 124 being designed to vibrate longitudinally at the same frequency as the sonotrode 108 and being dimensioned, therefore, according to equations already known to the art, as explained in the above-cited patent applications.

The coupler 122 is a tapered metallic element, brazed or otherwise rnetallurgically secured in end-to-end engagement with transducer 126, and slotted at its small end, at which end it is metallurgically joined, as by brazing, to

flange 120 of sonotrode 188, engaging about one-fourth of the periphery of flange 128, as shown in FIGURE 15. The coupler 12 i is similarly metallurgically secured in endto-end engagement with transducer 128, and similarly partially encircles and is metallurgically secured to flange 120 of sonotrode 1128, the points of engagement of the coupler members 122 and 124 to the flange 12% being opposed with respect to each other. These tapered coupler members 122 and 124, the cross-section of which may vary, and which may be round, square, or rectangular, may be one-half wavelength long longitudinally or may have a length equal to unit multiples of one-half wavelength longitudinally.

The transducers 126 and 128 each comprise a laminated core of nickel or other magnetostrictive metallic material. Each of the transducers 126 and 128 has a rectangularly shaped opening in its center portion, namely rectangularly shaped opening 130 in transducer 126 and rectangularly shaped opening 132 in transducer 128. The polarizing coil 134 and excitation coil 136 are wound through the rectangularly shaped opening 139 in transducer 126, and the polarizing coil 138 and the excitation coil 148 are wound through the rectangularly shaped opening 132 in transducer 128. Upon variations of the magnetic field strength of the excitation coils there will be produced concomitant variations in the dimensions of the transducers 126 and 128, provided that their respective polarizing coils 134- and 138 are charged at a suitable level with D.C. current. It will be appreciated by those skilled in the art that the frequency of the aforesaid variations, namely the expansion and/or contraction of the magnetostrictive transducers will be equal to the frequency of the alternating electric current flowing in their excitation coils.

The transducers 126 and 128 are each dimensioned to precisely identical dimensions as are the couplers 12.2 and 124 so that the vibratory energy delivered to the sonotrode 108 from transducer 126 and coupler 122 and from transducer 128 and coupler 124 is identical. The transducers 126 and 128 are driven in phase with each other, namely both transducers 126 and 128 are either simultaneously expanding or simultaneously contracting.

It is to be understood that the tranducers 126 and 128 should be properly dimensioned to insure axial resonance with the frequency of the alternating current applied thereto, so as to cause them to decrease or increase in length according to their coelficients of magnetostriction. The couplers 122 and 124 should resonate in length at the operating frequency of the transducers, so that vibratory welding transducer-coupling system 106 may operate efliciently under the welding process conditions. Moreover, the sonotrode 188 should resonate in torsion at the frequency of the transducers 126 and 128 and couplers 122 and 124 to minimize energy losses.

In place of the transducers 126 and 128 shown in the drawings, other magnetostrictive materials may be used such as the alloy 2V Perrnendur (an iron-cobalt alloy), a nickel-iron alloy, or Alfenol (an aluminum-iron alloy), each of which should be properly dimensioned to insure axial resonance with the frequency of the alternating current applied thereto, so as to cause it to decrease or increase in length according to its coeflicient of magnetostriction. Transducers of the aforesaid type presently constitute a preferred embodiment for operation at frequencies of up to about 75,000 cycles per second, although they may be used at higher frequencies. In place of the aforesaid metallic magnetostrictive materials, the transducer may comprise almost any material which has good physical properties and which changes its physical dimensions under the influence of electric potential or electric current. Thus, it may comprise a piezoelectric material, such as quartz crystals, or an electrostrictive material such as barium titanate, lead zirconate, etc. Such materials presently are preferably used at high frequency operations, as at frequencies above about 75,000 cycles per second, although they can be used at lower frequencies. The transducer may also consist of ferroelectric materials or an electromagnetic device, such as that which actuates a radio loudspeaker.

The leads 98, 100, and 102 project through the base 96 and are received Within socket 142 in torsionally rigid anvil 107. The flat uppermost surface of the anvil 107 engages the underside of the base 96.

In operation the transducer 126 and coupler 122 and the transducer 128 and coupler 124 vibrate sonotrode 108 torsionally. Thus, there is oscillating peripheral or circumferential motion of the sonotrode 112-8. The oscillating peripheral or circumferential motion of the tip portion 118 during the torsional vibration of the sonotrode 108 is in phase with the oscillating peripheral or circumferential motion of the free end portion 112 of the sonotrode 108, but is 180 degrees out of phase with the motion of the driven flange 120 which is metallurgically joined to the couplers 122 and 124 when the first overtone or second harmonic of torsional vibration construction is used.

Construction and operation of the sonotrode 108 to conform to the fundamental or first harmonic of torsional bar vibration has the disadvantage of offering but a single node and no loops intermediate the ends of the sonotrode 108; however, this construction is usable in some instances. Operations may be effected at other overtones where a larger number of loops intermediate the ends of the sonotrode is desired, for clearance purposes or for embodiments in which coupling to a large number of spaced couplers-transducers is effected to increase the power of the vibratory welding equipment. For example, three nodes and four loops are provided from one end of sonotrode 108 to the other when operation is effected at the second overtone or third harmonic.

As the face of annular tip 118 which is juxtaposed to the uppermost surface of the annular flange 98 of the cap 94 of the envelope 92 of transistor vibrates, it delivers energy to the plane of the contacted area of such flange 98. This effects vibratory welding between such flange 98 and the base 96 in the region in which the same are engaged with the annular tip 118 producing a ring-shaped weld. There is no spattering or contamination into the interior of the envelope 92 from the weldment so-produced.

An example of a satisfactory weldment between a cap 94 and a base 96 of a transistor is the following: a cap made of 2024 aluminum was ringwelded to a base made of gold-plated Kovar (an iron-nickel-cobalt alloy having a trademark of the Stupakotf Division of The Carborundum Company, Latrobe, Pa.) which contained lead wires and a fired ceramic insulation, by means of a three-coupler-three-transducer array attached to the sonotrode, said vibratory welding transducer-coupler system operating at a frequency of 20,000 cycles per second, using a power of 400 watts, a clamping force of 125 pounds, and a welding time of one second, with the weld being commenced at room temperature. A seal was made between cap and base by means of this ring weld which was air-pressure tested and which showed no signs of leakage when immersed in water with the inside of the cap-base pressurized at 15 pounds per square inch, and which upon subsequent cycling at 30 pounds per square inch and later at pounds per square inch for 30 minutes showed no sign of dye-penetrant leakage. The tube-type sonotrode used had an outside diameter of three-quarters of an inch and an inside diameter of one-half inch, to which was attached a three-eighths-inch annular tip. Removal of individual cap-base units after welding was effected by an air-ejection array operating inside the sonotrode.

In FIGURE 16 there is revealed an embodiment of the vibratory welding transducer-coupling system, like, which is also capable of operating at high power levels. It is another example of the symmetrical-drive-type array which, as provide by increase in strength of welds obtained, is able to deliver more effective energy for a given amount of power input than is possible with an unsymmetrical system. In the vibratory welding transducercoupling system 102 there is substituted for the anvil a second sonotrode with its associated couplers, transducers, and mass. Thus, in the embodiment shown in FIGURE 16 the metal workpieces 12 and 14 are welded together intermediate the sonotrode 16c and 16:22, with the clamping force being applied between such sonotrodes. The sonotrodes 16a and 16ee operate at the same frequency but are 180 degrees out of phase with each other. The general construction of the flange 56c on the sonotrode 16a and the flange 58ee on the sonotrode 162a and their associated couplers (couplers 36c and 38a in the case of flange 56e) (and couplers 40c and 42s in the case of flange 582(2); and the construction of their associated magnetostrictive transducers follows the construction shown in FIGURES 1 and 2, and need not be described herein. The use of opposed sonotrodes in the vibratory welding transducer-coupling system 10a permits high power levels of operation enabling such system to be utilized to effect weldments in relatively heavy sheets of metal.

In FIGURE 19, there is illustrated a partial plan view of metal members 200 and 202 joined together by a ringshaped or annular weld 204. Weld 204 was effected in the same manner as described above with the sonotrode tip contacting the weldment being elliptical in cross section. The metal members 200 and 202 are not joined together inside the annular or ring-shaped Weld 204.

In FIGURE 20, there is illustrated a partial plan view of metal members 210 and 212 joined together by an annular, non-circular weld 214. Weld 214 was effected in the same manner as described above with the sonotrode tip contacting the weldment being rectangular in cross section. The metal members 210 and 212 are not joined together inside the rectangular shaped weld 214. Similarly welds of other annular shape may be made such as square, hexagonal, octagonal etc. The sharp corners may be rounded off if desired. The members 200, 202, 210, and 212 may be any of the specifically identified metal members set forth above.

In connection with the mode of vibration described herein, there is a fixed angular displacement of the sonotrode (and therefore of the sonotrode tip) at a given power level, so that a circular weld presents an ideal condition wherein all points on the circle have the same radius from the center line of the sonotrode or sonotrode tip. However, when the weld outline departs from the circular, as in FIGURES 19 and 20, there is no convenient means for varying the welding pulse for different portions of the non-circular weld with its differing radii. Therefore, .difficulties may be encountered with underpowering and overpowering at different locations along the weld outline, giving possibilities of unsatisfactory welding and even excessive material deformation or cutting in some places. Such difliculties can be avoided if the ratio of maximum radius to minimum radius is not more than about to 1. Thus, in FIGURE 19 the radius 206 is not more than about five times as long as the radius 208. The point at which the radii 206 and 208 intersect represents the longitudinal center line of the sonotrode (with tip) utilized to effect the Weld 204. The same proportion holds true with respect to the radii of the weld of FIGURE 20.

The spotwelds 204 and 214 as well as weld 73 and the welds between cap 94 and base 96 are annular spot welds having the following characteristics: The weldment members were externally deformed at the Weld to an extent less than the welds are free from cast structure resulting from melting of the metal members when magnified 500 times, the welds have an interfacial region on the weldment members that is disturbed when the weld is viewed normal to the plane of the interface between the members. In connection with any of the welds described above, the Weldment members may be similar or different in chemical composition and physical properties and the welds may be a true annulus or may be an interrupted annulus as desired. In connection with the formation or" welds of types such as 204 and 214, sonotrodes 0r sonotrode tips modified :as to cross section may be utilized and preferably modified tips, inasmuch as modified sonotrodes present machining difficulties.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, since other means of effecting torsional vibration in a member or in members contacting the weldment can be adapted from other fields. Accordingly, reference should be made to the appended claims, rather than to the foregoing specification as indicating the scope of the invention.

It is claimed:

1. A ring-type weld between juxtaposed metal members which are externally deformed to an extent less than 10%, said weld being an ultrasonic weld essentially lacking a cast structure.

2. A weld in accordance with claim 1 comprising a true annulus.

3. A weld in accordance with claim 2 having at least 1 non-welded discontinuity.

4. A spot weld between juxtaposed metal members, said weld being at least partially arcuate in plan view, said metal members being externally deformed at the weld to an extent less than about 10%, said weld being free from a cast structure resulting from melting of the metal members when magnified 500 times, and said weld presenting an interfacial region on the metal members that is disturbed by vibratory energy when the weld is viewed normal to the plane of the interface between the met-a1 members.

5. A spot weld in accordance with claim 4 wherein said weld is a closed loop having inner and outer edges and being non-circular in plan view.

6. A spot weld in accordance with claim 5 wherein said weld is rectangular in plan view.

7. A spot weld in accordance with claim 5 wherein said Weld is elliptical in plan view, with the major radius of the elliptical weld having a length less than about five times the length of the minimum radius thereof.

8. A spot weld between juxtaposed metal members, said weld being a closed loop having discrete inner and outer peripheries, said metal members being externally deformed at the weld to an extent less than about 10%, said Weld being free from a cast structure resulting from melting of the metal members when magnified 500 times, said weld presenting an interfacial region on the metal members that is disturbed by vibratory energy when the weld is viewed normal to the plane of the interface between the metal numbers, and the maximum transverse dimension across the loop being less than about five times the minimum transverse dimension across the loop.

9. A spot weld in accordance with claim 8 wherein said Weld is rectangular in plan view.

References Cited by the Examiner UNITED STATES PATENTS 6/1949 Tramontini 219-82 3/1961 Roovers 189-36 X 

1. A RING-TYPE WELD BETWEEN JUXTAPOSED METAL MEMBERS WHICH ARE EXTERNALLY DEFORMED TO AN EXTENT LESS THAN 10%, SAID WELD BEING AN ULTRASONIC WELD ESSENTIALLY LACKING A CAST STRUCTURE. 